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I know I am fairly new here, but I am loving it! I did want to mention a cheap alternative! You can buy a couple sheets of posterboard, slap some spray adhesive between the two and use a rolling pin to create a thicker (structurally sound) board. They can be layered to your desired thickness this way! Plus they take a resin coat like a champ!

Just my 2 Cents! Keep up the good work all of you!

Ghostwalker said:

paper/poster board is too thin, it'll be really hard to make structurally sound.
i got Mat Board from Michaels Arts and Craft, Studio Decor 24in x 36 in.
plan on using 3 sheets for 2 buckets barring messups.
you won't find it with the regular cardboard/craft paper/corrugated but rather with their picture/painting frames.

edit: just double checked my Mat Boards thickness and it clocks in at 1.58 mm or 1/16 in.

I have been working on my build now for a god bit. It's taught me quite a bit about patience! I am working on my second cheek structure (molding and shaping) Anyway - I tried the drywall putty... i know! i know! I just used a very tiny bit to fill in my gaps. Its going to be fine. I will begin with bondo in a bit. i have reservations about it though. Cardboard and bondo... Bondo is so thick and sticky... I just hope its not too heavy and cumbersome for my little baby. PS This helmet fits me great.
Here is another one with the recent cutouts and you can see the bit of drywall spackle - i plan on sanding as much off as possible - I will get brave and use the bondo.
The cheeks are just sitting there getting the feel for their new home.
Its funny - the pictures don't do it justice... i will continue working and post more pics soon. Thanks for all the assistance WOF and Antman - you compliment each other nicely.

Friend, thank you for posting your work, served me as inspiration.
The pictures above are no longer available. could consult?

This is amazing ! Im working on my own bucket. Im using the same exact templates that you use, but i lack experience. Hope my next attempt will result in something like this ! Im proud of you Ant Man ! Greetings from Argentina

Are you gonna leave us hanging? What's happening? The tutorial has been brilliant! I've followed all the way and I'm just building the stalk. I've also found your first cardboard build but it wasn't as detailed, tutorial-wise as this. What happened? Did you finish it? Have I missed something? C'mon back and give us your wisdom and your pictures and advice!! Please!!

Hi Antman! I´ve started my bucket yesterday.. I am following Your instructions, it is great! I hope it will look like yours
But I found that my templates are a bit small, so I had to re-print them correctly, now they are fine